CONTACTAlcon Components LtdApolloTamworthB79 7TN+44 (0) 1827 72 37 00

PORSCHE 997 TURBO

Many owners know that, under extreme conditions such as those achievable at the track, thelimits of the standard Porsche 997 Turbo brakes can be exceeded, sometimes resulting in a substantial deterioration in brake performance.

UPGRADE?

Alcon’s 997 Turbo SuperKit front & rear brake package offers a range of benefits to improveyour car’s braking performance.

WHAT IS THE OSCA PROCESS?

Each application presents its own challenges, as well as specific wheel diameter, vehicle mass,power and brake requirements. The OSCA design process can be applied using parameters ofany application to develop an optimised design. The steps in the OSCA process are as follows:

1. Benchmark previous caliper design

An existing caliper design is identified for use as a benchmark for setting up performancecriteria. The actual caliper is then subjected to a number of physical laboratory tests to validatethe computer generated results.the computer generated results.

2. Define performance targets

Starting with the benchmark data and using information about the application, issues to beaddressed and the customer’s specific requirements, target values for parameters such asdeflection (stiffness) and mass are set.

3. Define packaging envelope

The packaging envelope is the total volume available for the caliper and is usually dictated by theinternal profile of the vehicles wheels, as well as the position of the other items such as theinternal profile of the vehicles wheels, as well as the position of the other items such as thesuspension components.

4. Specify fixed design elements

Elements such piston sizes and positions, pad abutment locations and mounting points arespecified by the applications engineer. The caliper design is optimised around these fixed designelements and within the packaging envelope.

5. Set boundary conditions

The forces exerted on the caliper during normal operation and the manner in which the caliperThe forces exerted on the caliper during normal operation and the manner in which the caliperis constrained to move must be accurately determined.

6. Apply stiffness constraints

Using optimisation software, material is removed from the packaging envelope until the specifiedstiffness constraints are reached.

7. CAD surfacing

Once the main optimisation phase is complete, the model is then CAD surfaced to produce amore workable model.more workable model.

8. Stress analysis

Further stress analysis is performed on the surfaced model. The more accurate results gainedenable further design refinement.

9. Final design for manufacture and function

Once a model has been created that meets all of the performance targets, functional elementssuch as fluid passages and bleed ports are added.

10. Confirm stress analysis10. Confirm stress analysis

Stress analysis is repeated on the functional design to ensure performance remains withinlimits.

11. Finished product

Following the final stress analysis, the caliper assembly becomes a finished product when allcomponents are added, including pistons, seals and bleed screws. The caliper is now ready forproduction and use on the vehicle.

FRONT BRAKE PACKAGE

The front brake caliper has been designed using Alcon’s OSCA design process. Featuring amonobloc construction, the caliper has been machined from a single piece of aluminium billet.It has been configured to work with a 390x34mm disc, offering sufficient clearance within the standard wheels.

The caliper is designed to bolt directly onto the standard upright, requiring no additionalbrackets or mounting hardware.

Through the use of Alcon’s OSCA design process, the caliper provides a highThrough the use of Alcon’s OSCA design process, the caliper provides a highlevel of stiffness in comparison traditional calipers.

The front disc is a 390x34mm unit, offering a significant increase in pad area along with anincrease in mass, both of which contribute to an increase in thermal capacity. The largerdiameter also contributes to a higher level of available brake torque over the standard discs.They use Alcon’s high performance road car semi-float drive to allow thermal expansion underload and help reduce brake noise.

The kit is supplied with Pagid RS9-2 pads and braided brake lines to aid fitment.The kit is supplied with Pagid RS9-2 pads and braided brake lines to aid fitment.

REAR BRAKE PACKAGE

The rear brake caliper has been designed to work with a 385x33mm disc, offering sufficient clearance within the standard wheels.

The caliper is configured to bolt directly onto the standard upright, requiring no additionalbrackets or mounting hardware.

The caliper is a bespoke design, offering a significant reduction in weight, through utilisation ofmonobloc construction from aluminium billet. The caliper has 6 pistons for maximum availablebrake torque while retaining the standard brake balance for consistent pedal feel.brake torque while retaining the standard brake balance for consistent pedal feel.

The rear disc is a 385x33mm unit, offering a significant increase in pad area along with anincrease in mass, both of which contribute to an increase in thermal capacity. The largerdiameter also contributes to a higher level available brake torque over the standard discs. Theyuse Alcon’s high performance road car semi-float drive to allow thermal expansion under loadand help reduce noise. The disc assemblies use an aluminium bell with a cast iron insert for compatibility with of the standard parking brake mechanism.

CONTACT US

Ben Edwards - Motorsport Sales Manager

Alcon Components Ltd

ApolloTamworthStaffordshireB79 7TNEnglandEngland

T +44 (0) 1827 72 37 00

F +44 (0) 1827 72 37 01

E info@alcon.co.uk

www.alcon.co.uk

PRICE LIST

Part Number

BKC1759ZG04

Description

SuperkitPainted calipers / Semi-float discsPagid RS9-2 friction material

Retail

For pricing detailsplease contact yourlocal Alcon dealer